Acoustical roof deck



July 9, 1935. w KUEHNE 2,007,374

ACOUSTICAL ROOF DECK Filed July 25, 1932 2 Sheets-Sheet l INVENTORWILLIAM KUEHNE.

ATTORNE July 9, 1935. KUEHNE I 2,007,374

ACOUSTICAL ROOF DECK Filed July 25, 1932 2 Sheets-Sheet 2 'INVENTORW\LL\AM KLJEHNE.

ATTORNE Patented July 9, i935 UNITED STATES PATENT OFFICE ACOUSTICALROOF 'DECK William Kuehne, Chicago, Ill., assignor to United StatesGypsum Company, Chicago, 111., a cor- Duration of IllinoisApplication'July 25, 1932, Serial No. 624,379

I: Claims. (01.108-13) This. invention relates to building constructhelongitudinal junction with an adjoining roof tions, and has referencemore particularly to deck, metal roof decks having sound absorbing ma-Fig. 7 is a sectional elevation through a tool terials assembled withthe deck to form a unit. for forming slots in the legs of the roof deck,and In correcting acoustics in industrial buildings, Fig. 8 is asectional elevation through a ma- 5 schools, etc., I have found itdesirable to utichine for forming slots in the legs of the roof lize acombined metal roof deck having dependdeck. ing, U-shaped ribs, with asound absorbing pad The roof deck element forming a part of my facedwith a perforated metal membrane, the mproved construction comprises aplate In on whole being assembled at the factory and Shipped which areformed preferably a plurality of out- W to the job as a unit. In makingsuch a unit, I wardly extending, integral, U-shaped ribs II. An preferto'have, individual elongated perforated tw rdly ex n i l n n l flangeI2 i membranes having outstanding legs fitting beformed on one edge ofthe plate It! and an outtween the legs of the roof deck, and supportsaid Wardly e e ding U-shaped rib orchannel I3 is l-) membranes from thelegs of the roof deck by formed on the opp longitudinal e of sa dmembers which are inserted into apertures deck plate. Beads M are formedin the plate I0 fo med in t roof deck legs, s difficulty between theribs, said beads extending from one has been experienced in formingapertures end Of the deck to a point short Of the other end in the legsof the roof deck so that all of said of e decke b ads l4 serve to reducethe apertures are of equal distance from the con-- width of the PlateSection adjacent one d 20 necting web of the roof deck legs. of o dookplate so that Wdde p ates have An object of this invention, therefore,is to summer clearance to ,telescoplcally ve lap end provide anacoustical roof deck unit which may to end to form root. h roof decks aso be conveniently Shipped in an assembled telescope along theirlongitudinal edges with the r dition to the job for easy and quickerection. flange of 0.119 roof deck hoh 1n the ohan- Another object ofthe'invention is to provide Shaped nb of h adlolmhg o deck a method offorming apertures in the legs of i Roof deck plates are Supported uponmetallic roof decks so that said apertures are su table steel frameworkIlla and. are preferably all of equal distance from the webs of the roofcovered on the upper surface by a Sheet of fiber deck ribs.

A further object of the invention is to provide' an acoustical roof deckin which assembly of the various parts or theroofdeck are convenientlymade by means of elongated support board being covered with asphaltshingles I! or other suitable weather protective coating.

Supported between legs 18 of the ribs II, are

provided elongated perforated metal membrane members which support boththe perforated memlfsfi g ffl 32;:ggg fgf gg ifi ggi 3') o d and theaioustlcal Pads; alsovto Improve thereof. Holes 2|, preferablytriangular shape bu oonstlllotlohs and their method of m or any otherdesired shape such as round oval ll in oiher respects heremafterspeclfied etc., are formed uniformly over the surface bf the a d cmembrane [9. In order to support the mem- Reference is to be had to theacqompanyieg brane sections I9 between the ribs l I, I form drawing-f1forming a Part of tms'speclfica'fion' m apertures 24 in the legs I8,said apertures in a which given length being uniformly spaced .above theFig.1 is a perspective, sectional view ofa roof tt of th ribs II. Theapertures may be e dy y improved construction, formed by a tool 26having jaws terminating in 45 F g. 2 is a perspective View of a roof oinwardly extending, opposed punches 21. Durtlon, v a ing the punchingoperation, an elongated die Fig. 3 is a persp Sectional view ofa 28having longitudinal grooves 29, is inserted perforated metal, membraneunit, I v in-a'rib in such a way that the punches 21 serve Fig. 4 is asectional elevation through the to force the metal of the rib legs I8into the 50 acoustical roof deck.- grooves 29 and formseveredshoulders'30 in the Fig. 5 is a. longitudinal sectional elevation 'legsl8. If desired, all of the'apertures 24 may throughtelescopingacoustical roof de'cks,' be punched simultaneously in a roofdeck see- Fig. 6 is a. sectional elevation through a slighttion-by meansof rotary cam cutters 3| mounted I ly modified form of the acousticalroof deck at upon shafts 32 which are rotatably mounted in 55 board I6serving as heat insulation, this fiber 30 ously or intermittently bymeans of automatic controls not shown associated with the shaft 31,

form the apertures 24 by a single rotation of .the

cam cutters 3| without stopping the roof deck.

In order to absorb the sound passing through the movement of theperforations 2| in the membrane I9, I provide a fibrous pad 40' of soundabsorbing material such as mineral wool, hair felt, etc. In order tosupport the pads 40in spaced relation to the. membranes I9, I provideU-shaped wire hangers 4| having upstanding legs 42 which terminate inoutstanding ends 43, the latter engaging in the apertures 24 to lie ontop of the severed shoulders 30, the outward movement of the hanger ends4'! being limited by engagement with the offset metal pads 29a formed bythe punches 21, When using pads 40 which are fairly flexible, it ispreferable to provide zigzag sections formed 'in the wire hangers 4| forthe purpose of supporting abutting ends of adjoining pads "where theends of the roof decks telescope to prevent said pads from saggingbetween hangers and contacting with the perforated membranes l9. Theoutstanding hanger ends 43 also pass through apertures formed in themembrane legs- 20 whichare positioned to register with the apertures24.- It will be noted that hangers 4| thus support both the membranesections l8 and the flbrous pads 40 by engagement with the shoulders 30.The pads 40 are supported out of contact-with the membranes 19 so thatthe lower surface of safidmembranes may be washed or cleaned fromtime totime as they become soiled'without causing the pads 40 to become wet bythe wash water.

By the use of the punch 28 and dies 28, the

. apertures 24 are formed,at a uniform height above the bottom of ribsII at all times thus insuring that the bottom faces of membrane sectionsi9 all lie in a uniform plane slightly above the bottoms of ribs ll.Where the longitudinal lap of roof decks occurs (Fig. 6) the outstandinghanger ends 43 may be made slightly longer to allow for the thickness ofthe roof deck flange I 3 which will lie between the flange I! of the cadjoining roof deck and upstanding legs 20 of one of the membranesections l9. In Figure 6, the constructionis slightly modified in thatthe metal is not severed adjacent shoulders 30a thus making the roofdeck a water-shed immediately upon erection.

I would state in conclusion that while the illustrated exampleconstitutes a practical embodiment of my invention, I do not wish tolimit myself precisely to these details, since manifestly, the same maybe considerably varied without 1. In an acoustical roof deck, a metalsheet v having a plurality of U-shaped stiffening ribs, the legs of saidribs being provided with aperdepartlng from the spirit of the inventionas detures, perforated metal membranes having outstandingflangesjfltting between said ribs and having apertures registering withthe apertures of said ribs, U-shaped support members having outstandingends 'passing through the registering apertures of' said flanges andlegs, and a sound absorbing pad supported by said members in spacedrelation to said membrane.

2. In an acoustical roof deck unit, a perforated, elongated, metalmembrane having outstanding flanges formed on the longitudinal edgesthereof, U-shaped support memliershaving outstanding ends extendingthrough apertures formed in said flanges, and a sound absorbing padsupported by said support members to form an acoustical unit.

3. In an acoustical; roof deck, an imperforate metal plate havingintegral outstanding ribs pressed from said plate, a perforated metalmembrane extending between said ribs in spaced parallel relation to saidplate, support members extending between said ribs and having the ends5.'In an acoustical roof deck, a metal plate having integral apertured,outstanding U-shaped ribs pressed from said plate, U-shaped wireextending between said ribs and having outstanding ends extending intothe rib apertures, and a sound absorbing pad and perforated metalmembrane supported by said wires.

6. In an acoustical roof deck, a metal plate having apertured,outstanding ribs, a perforated metal membrane extending between saidribs. wiresupport members having outstanding ends extending into theapertures of said ribs, zigzag bends in said wires between said ribs,and a sound absorbing pad supported by the bends of said wire supportmembers.

7. In an acoustical roof deck, a metal plate having outstanding,U-shaped ribs, struck out pads formed in said ribs forming severedshoulders, support members having outstanding ends supported on saidshoulders and bearing against said pads, perforated metal membraneextending between said ribs, and a sound absorbing pad supported by saidsupport members.

